Lighted auto visor mirror

ABSTRACT

A visor for use in a vehicle is disclosed. The visor comprises a pivot rod and a first and second shell being engagable to form a visor body. The visor also comprises a vanity and a mirror having at least one clear portion arranged at or near an end thereof. The visor also comprises a circuit board secured to the first shell and a light emitting diode secured to a surface of the circuit board. The visor also comprises a ramp arranged in a back surface of the mirror wherein the ramp is aligned with at least one clear portion of the mirror. The visor mirror having a ramp arranged therein may allow for light to be redirected towards the user of the mirror from the LED.

This Continuation Application claims benefit of pending U.S. patentapplication Ser. No. 15/420,176, filed on Jan. 31, 2017

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention generally relates to a sun visor for interior usein a vehicle, and more particularly relates to a sun visor, having avisor body that includes a vanity having a light emitting diode.

2. Description of Related Art

Sun visors are well known and widely used in the prior art. Manydifferent types and designs have been successfully employed in vehiclesover the years. Many of these prior art visors have been developed in avariety of ways through which visor bodies and other interior componentsmay be constructed and mounted within a vehicle. Advances in design mayoften add complexities to the manufacturing processes for interiorcomponents. There has been and continues to be a pre n in the automotiveindustry on cost savings, weight reduction, and improvements in theefficiency and speed in the manufacturing processes for such componentstherein. One area of particular focus in the automobile technology fieldhas been reducing the number and the complexity of steps and partsrequired to assemble interior components such as sun visors or visorsfor use in a vehicle.

Some prior art visor designs use a clam shell which allows for a visorbody to be constructed relatively quickly and easily, however, thevarious components that are attached to the visor clamshell halves mustin some cases be incorporated with several assembly steps prior tosecuring the clamshell halves together. For example, several knowndesigns require insertion of additional mounting or journaling piecesfor retention of the visor pivot rod within the visor body. Theconstruction of visors having such a design is relativelytime-intensive. Moreover, the various slides, journals, retainers, etc.,utilized in the construction may add significant expense and weight tothe overall visor, along with unwanted noise and increase the number ofcomponents necessary to build a visor. Many of these prior art visorsuse standard light bulbs, such as incandescent bulbs to provide lightfor either a vanity which includes a mirror arranged within the visor orfor a map light that is sometimes arranged within the visor. The use ofthe incandescent bulb draws more current and power than that of newertechnologies, such as a LED bulb.

In some prior art visors, eliminating parts may reduce the expense ofmanufacturing and constructing the visor. Decreasing size and weight,however, can be accompanied by decreases in strength. Furthermore, thevisors that attempt to change well accepted technology, likeincandescent light bulbs with new technology, such as a LED, may runinto problems with consumers and users of the vehicle not accepting thelook and feel of the light emitted by an LED versus that of a lightemitted by an incandescent prior art light bulb. The use of newtechnology, such as a LED over a prior art light bulb, may increase theefficiency and reduce manufacturing assembly times for visors in theautomotive and other vehicular art. Many of these prior art visors use alighted mirror that contains two light bulbs, generally one on the leftside and one on the right side of the mirror so that the person's faceis illuminated when they look into the mirror. Hence, it is desirable inthe art to provide a visor that is light weight, easy to manufacture anduses relatively few components, yet utilizes a design impartingsignificant durability to withstand heavy and repeated use and toprovide a solid construction with tight tolerances throughout the entiresystem. Furthermore, there is a need in the art for an improved visorthat has a LED lighted vanity and/or map light arranged therein. Therealso is a need in the art for a sun visor that uses a variety of methodsof aligning a LED with a mirror that has an integrated light guidetherein. There also is a need in the art for a mirror that may includeeither one or two LED's arranged therewith and to be used in conjunctionwith an integral or internal light guide of the mirror to provide a moreeven appearance and distribute the light in a more aesthetic pleasingmanner than prior art light bulbs. There also is a need in the art for avanity that may use one light to light both sides of a vanity mirrorthrough the use of an internal or integral light guide system arrangedwithin the body of the mirror along with at least one ramp arrangedwithin the body of the mirror.

SUMMARY OF THE INVENTION

One object of the present invention may be that it provides an improvedvisor,

Another object of the present invention may be that it provides a visorthat has a light emitting diode for use in illuminating a mirror of avanity.

Yet a further object of the present invention may be that it provides avisor that uses a LED as a direct replacement for a prior art lightbulb,

Still another object of the present invention may be that it provides avisor that uses a LED as the light source in conjunction with a mirrorhaving a light guide integrated within a body thereof.

Still another object of the present invention may be that it provides avisor that includes a mirror having at least one ramp arranged in a backsurface thereof for redirecting light towards the user of the vanitymirror.

Still another object of the present invention may be that it provides avisor that includes a wire arranged between a circuit board and theelectrical system of the vehicle to provide LED lighting in a visorvanity.

Still another object of the present invention may be that it provides avisor that is easier to manufacture and More efficient through the useof a LED lighted vanity.

Still another object of the present invention may be that it provides avisor that is more robust and includes a lighting system that is morereliable and longer lasting than prior art lighting systems.

Yet another object of the present invention may be that it provides avisor that has a mirror that allows light to enter its edge and travelacross the plane of the mirror by total internal reflection.

Still another object of the present invention may be that it provides avisor having an LET) and mirror that has clear ends arranged at or nearone or both ends thereof.

According to the present invention, the foregoing and other objects andadvantages are obtained by a novel design for a visor for use in avehicle. The visor generally comprises a pivot rod and a first andsecond shell being engagable to form a visor body. The visor alsocomprises a vanity and a mirror having at least one clear portionarranged at or near an end thereof The visor also comprises a circuitboard secured to the first shell and a light emitting diode secured to asurface of the circuit board. The visor also comprises a ramp arrangedin a back surface of the mirror, wherein the ramp is aligned with the atleast one clear portion of the mirror in order to redirect light fromwithin the mirror toward the user of the vanity mirror.

One advantage of the present invention may be that it provides for animproved visor.

A further advantage of the present invention may be that it provides fora visor that uses a LED as the light source for a vanity.

Yet another advantage of the present invention may be that it providesfor a direct replacement of a prior art light bulb with a LED arrangedon a circuit board for a vanity in a visor.

Yet another advantage of the present invention may be that it providesfor a mirror having an integral or internal light guide arranged withina body thereof such that light from the LEI) may enter one end of themirror and pass across the entire length and plane of the mirror.

Still another advantage of the present invention may be that it providesa visor that uses a LED in conjunction with a mirror to provideillumination for a vanity via ramps arranged in a back surface of themirror.

Still another advantage of the present invention may be that it providesa visor that replaces prior art light bulbs with more energy efficient,reliable and longer lasting LED light sources.

Still another advantage of the present invention may be that it providesfor a visor that is easier to manufacture and more robust than prior artvisors.

Yet another advantage of the present invention may be that it providesfor a visor that uses a LED in conjunction with a mirror having at leasta clear end on one or both ends thereof to illuminate the mirror and theuser of the vanity mirror.

Still another advantage of the present invention may be that it providesa visor that uses either one or two LED's to provide illumination for amirror in a vanity of a visor.

Other objects, features and advantages of the present invention willbecome apparent from the subsequent description and appended claims,taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a plan view of a visor according to the present invention,

FIG. 2 shows a plan view of a visor according to the present invention.

FIG. 3 shows a plan of a visor according to the present invention.

FIG. 4 shows a cross section of a visor according to the presentinvention.

FIG. 5 shows a top view of a visor according to the present invention.

FIG. 6 shows a bottom view of a mirror of a visor attached to a vanityframe according to the present invention.

FIG. 7 shows a top view of a mirror attached to a vanity frame accordingto the present invention.

FIG. 8 shows a cross sectional view of a mirror attached to a vanityframe according to the present invention.

FIG. 9 shows an edge view of a mirror attached to a vanity frameaccording to the present invention.

FIG. 10 shows a top view of a mirror for use in a visor according to analternate embodiment of the present invention.

FIG. 11 shows a side view of a mirror for use in a visor according to analternate embodiment of the present invention.

FIG. 12 shows a close up view of a ramp for use in a mirror according toan alternate embodiment of the present invention.

FIG. 13 shows an edge view of an alternate embodiment of a mirrorsecured in a vanity frame according to the present invention.

FIG. 14 shows a top view of an embodiment of a mirror for use accordingto the present invention.

FIG. 15 shows side view of an embodiment of a mirror for use accordingto the present invention.

FIG. 16 shows a close up view of an embodiment of a mirror for useaccording to the present invention.

BRIEF DESCRIPTION OF THE EMBODIMENT(S)

Referring to the drawings, there is shown a visor 20 according to anembodiment of the present invention. Generally, the present inventionbroadly provides a clam shell type vehicle sun visor 20 having a pivotrod 32 mounted to a carrier, wherein the pivot rod 32 and carrier areslidably captured during assembly with a single step of attaching visorshell portions together. The carrier thus rides in the visor body 22itself rather than a separate carrier and is preferably retained betweensurfaces and/or features, such as channels molded integrally within theshell portions. Similarly, the pivot rod 32 rides in the visor body 22and a separate bracket, bezel or similar piece is not necessary tosupport the pivot rod 32. Related aspects of the present inventioninclude methods for manufacturing a sun visor 20 also described herein.Furthermore, it should be noted that the visor 20 as shown in thepresent application can be used in any known type of vehicle, such asbut not limited to, automotive vehicles, maritime vehicles, aerospacevehicles, military vehicles, trains, and any other known vehicle thathas a need for the sun to be blocked from filtering into the interiorcompartment of the vehicle. It should also be noted that generally allof the components of the visor 20, according to the present invention,may be made of a plastic material that is capable of either beingextruded, molded or shaped by any known manufacturing process. However,any other known metal, ceramic, plastic, composite, natural material orany other known material may also be used for any of the parts orcomponents of the visor 20 described herein. Furthermore, it should benoted that the visor 20 of the present invention may be any known typeof visor, such as a sliding visor, a non-sliding visor, a moveablevisor, or any other type of visor known in the vehicle industry.

In one embodiment shown in the Figures, the visor 20 includes first 24and second shell halves 26 or shells which are engageable to form anelongate visor body 22. Various molded features may be included on eachshell to facilitate engagement of the shells 24,26. For example,complementary structures may be formed on the respective visor shells24,26 that allow a snap-fit therebetween. In one contemplatedembodiment, the shells 24,26 may be formed having integral or connectedlongitudinal peripheral edges. Other embodiments are contemplated inwhich shells are formed as separate, unconnected be s. Althoughconnected shells are preferred, the visor as shown in the Figures mayhave unconnected shells also. The visor 20 further may include a pivotrod 32 that is arranged into one end of the visor body 22 and connect onthe opposite end to a headliner or roof of the vehicle into which thesun visor 20 is arranged. The visor 20 is preferably formed such thatthe shells 24,26 may be closed about pivot rod 32 and as such capturethe pivot rod 32 therebetween in a single assembly step. Also, the visor20 may include a carrier which is slidably captured by the closure orengagement of the shells 24,26, slidably securing the carrier betweenthe shells 24,26 without the need for installation of an internal slidemember, retainer or similar mechanism for mounting the pivot rod 32. Allof the components and parts of the visor 20 may be manufactured from anyknown material and by known processes, such as but not limited to, anytype of plastic, metal, ceramic, composite, natural material or anyother known material, and by any type of molding technique, formingtechnique, chemical and mechanical process to design and make thecomponents as described herein.

Generally, the shells 24,26 are formed by injection molding a plasticmaterial in a conventional manner. For example, the shells 24,26 may beformed from a molded polyethylene, or by some other suitable methodand/or material. The first and second shells 24,26 generally includeretaining surfaces in any known shape, such as arcuate retainingsurfaces, flat or angled retaining surfaces, all of which may beelongate or trough shaped surfaces extending parallel to an edge of avisor shell and defining a portion of a cylinder or wall. It shouldfurther be appreciated that the present invention may encompass designswith retaining surfaces that vary in dimension between longer,trough-shaped features and more narrow arcuate ledges as shown. Itshould further be noted that an arcuate pair of surfaces may be alignednear one end of the visor shells 24,26 to allow for the pivot rod 32 tobe properly supported and capable of rotating and sliding with relationto the visor body 22. The visor half shells 24,26 also may have achannel formed near one edge thereof, wherein the channel may have afirst and second bearing surface. These bearing surfaces may be arrangedat any known angle with relation to a center line of the visor body 22.In one contemplated embodiment, these angled surfaces may be arranged oneach side of a channel that extends a predetermined distance along alongitudinal axis of the visor body 22 and these angled surfaces may beany approximate angle with relation to a center line of the visor body22. It should be noted that these angled bearing surfaces may bearranged on each inner surface thereof. It should also be noted that thevisor half shells 24,26 may include other surfaces that receive and holdvarious components of the sliding visor 20, such as but not limited tothe pivot rod 32, a D-ring, a vanity 28, and covering material 30arranged over the visor body 22 to complete assembly thereof.

The shell halves 24,26 that form the visor body 22 of the visor 20according to the present invention also may include a plurality ofhybrid snap and ultrasonic weld joints. In one contemplated embodiment,a plurality of profile snaps may be arranged around the front edge andthe side edges of the arcuate shells of the visor shells 24,26. One ofthe shells may have the male portion of the profile snap while the othershell may have the female portion, which receives the male portion andholds the first shell to the second shell in order to provide a robust,zero flex interface between the two half shells 24,26 to form a robustvisor body 22. These snaps, which may be arranged around the outerprofile, may allow for enough flex for the front edge and side edges toallow for a tucking process to occur as described hereafter. The visorbody 22 may also include at least one weld bar joint and at least oneweld boss joint arranged at a predetermined position on the visor body22. It should be noted that other contemplated methodologies andfasteners may be used to secure the two visor shell halves 24,26 to oneanother and it is also contemplated that the visor 20 is formed as onesingle body member and not of two separate shell halves.

One of the shell halves also may include a predetermined shaped orificeor cavity 32 on an outer surface thereof that may be used to receive andsecure a vanity 28 to the visor body 22. The orifice or cavity 32 forreceiving the vanity 28 may include a plurality of locking surfaces orlocking arms 34 that may interact with locking surfaces or flanges 38 ofa frame 36 of the vanity 28 to ensure the vanity 28 is secured to theouter surface of one of the shells of the visor body 22. These lockingsurfaces and arms 34 may take any known shape and are arranged such thatboth illuminated and non-illuminated visor vanities may be arrangedtherein. Other surfaces may also be molded into the visor half shells24,26 to allow for placement of wires 40 to illuminate a visor vanitymirror 42 or to receive a universal garage door opener or othercomponent directly into the visor body 22. The visor half shells 24,26according to the present invention, may also include a plurality ofteeth arranged around an outer periphery of the front edge and sideedges of each of the shell halves 24,26. These teeth generally have apyramidal or triangular like shaped tooth and may either be directlyaligned with one another from each half shell or offset with one anotherfrom each half shell, depending on the design requirements and thetucking process to be used. This use of the teeth to form a tuck edgeand to have the cover material placed by a tuck edge process intoengagement with the teeth may create an aesthetically pleasing visorbody 22 having a crisp and clean outer cover material 30 arrangedthereover. It should be noted that in one contemplated embodiment thecover material 30 may be formed in the shape of a sock, wherein the sockis arranged over one end of the visor body 22 then the tuck process isused to create the clean front edge and side edges of the visor 20.However, any other known tuck process and cover material that is not inthe form of a sock may also be used depending on the design requirementsand the visor being created.

The visor 20, according to the present invention, may also include aD-ring secured to the visor body 22 on a top edge thereof. The D-ringmay be any known D-ring. The D-ring of the present invention maypartially assist in holding the cover material in a taught, clean mannerover the outer surface of the visor half shells formed into a visor body22. It should be noted that any shape may be used for the D-ring bodyand D-ring pin associated therewith. The visor 20 may include a pivotrod 32 which is attached at one end to a bracket or connector 44 whichis secured to the headliner or roof of a vehicle. The bracket 44 mayhave a connector secured thereto to connect the electrical system of thevehicle via a wire 40 to the bracket 44, the wire 40 is then passedthrough the pivot rod 32, which generally is hollow according to thepresent invention. However, it should be noted that a solid pivot rodmay be used, as long as it will be capable of passing electricitytherethrough to allow for illumination of the vanity mirror 42 ifnecessary or map light. The bracket 44 may be secured to the roof of thevehicle via fasteners or any other known methodology. The bracket 44 mayinclude an orifice that will receive one end of the pivot rod near anelbow of the pivot rod 32, wherein the pivot rod 32 generally has anangle of 60°-120° at the elbow. The pivot rod 32 may be secured andcapable of rotation within the orifice of the bracket 44 and may also beswung between a front windshield of the vehicle and a side window of thevehicle to block the sun from any angle. The pivot rod 32 may be of anyknown length and diameter depending on the design of the visor 20 andthe automobile into which it is arranged. The wire 40 may be connectedbetween the electrical system of the automobile and a LED forillumination of a visor mirror. 42 in the vanity 28. It should be notedthat the visor 20, pivot rod 32 and bracket 44 may be made of any knownmaterial, such as but not limited to plastic, ceramic, composites,metals, or natural material, etc.

The visor pivot rod 32 maybe arranged within a carrier that is arrangedwithin he visor body 22. The carrier is capable of slidable movement ifthe visor is a sliding visor. If the visor is not a sliding visor, thecarrier is fixed with respect to the visor body 22. In the sliding visorthe carrier may slide within a channel of the visor body 22 to allow forthe visor 20 to be extended out towards an end of the visor rod 32secured within the visor body 22. Any known carrier may be used tosecure the pivot rod 32 to the visor body 22, such as but not limited toa floating carrier, a fixed carrier or any other known carrierassociated with a visor rod 32 and visor body 22.

The visor 20 may also include a wire routing system that passes a wire40 from the bracket 44 through the pivot rod 32 to the LED vanity light46 for illumination of a vanity mirror 42 therein. Any known wirerouting system may be used to pass the wire 40 through the visor body 22to a circuit board 48 used to control and operate an LED 46 thereon. Itshould further be noted that it is also contemplated to use an onboardelectric source to illuminate the LED 46 of the vanity 28 for the visor20.

The visor 20 also may include a vanity 28. The vanity 28 generallyincludes a vanity frame 36, vanity door 50, door springs 52, a vanityspring, and a vanity mirror 42, with optional lights arranged thereon.The vanity frame 36 generally may include at least one, but in theembodiment shown, two connecting flanges 54 arranged near or at a bottomsurface of the vanity frame 36. The opposite end of the vanity frame 36may have arranged therein at least one locking shoulder or lockingmechanism 56 that may interact with locking tabs or locking surfacesarranged on a surface of one of the visor shell halves 24,26. This mayallow for the vanity frame 36 and vanity 28 to be secured to the visorbody 22 without fasteners, such as screws, etc. However, it should benoted that another embodiment may use fasteners and screws to connectthe vanity frame 36 to the visor body 22. One contemplated embodimentmay create a snap in vanity 28. Generally, the vanity frame 36 and door50 may have a rectangular or oval shape, however any other shaped vanitymay be used depending on the design requirements of the visor 20. Thevanity frame 36 may also include a hook or flex hook 58 arranged at oneedge thereof and a leaf spring 60 arranged near a middle portion of anedge of the orifice defined in the middle of the vanity frame 36.Adjacent to the leaf spring 60 may be one or two locking tabs 62. Thiscombination of the at least one flex hook 58 and in the embodiment shownthree equal distantly spaced flex hooks 58 extending from vanity frame36, the leaf spring 60 and locking tabs 62 may be used to secure themirror 42 to the vanity frame 36 in a flexible interface withoutadhesives. In operation, the mirror 42 is placed under the flex hooks 58and then snapped under the locking tabs 62 and against the leaf spring60 to secure the mirror 42 without adhesives to the vanity frame 36.However, it is also contemplated to secure the mirror 42 to the vanityframe 36 with adhesives or any other methodology. Hence, the vanitymirror 42, which may be of any shape, size or thickness, may be held inplace to the vanity frame 36 without adhesives, which are generally usedto hold a vanity mirror 42 to a frame 36 in the prior art. It should benoted that any number of leaf springs, locking tabs and/or flex hooks orflanges may be used to hold the vanity mirror 42 according to thepresent invention. The vanity frame 36 may be inserted into the visorbody 22 by securing the first and second flange 54 arranged near abottom edge of the vanity frame 36 underneath inboard hooks or lockingsurfaces that are molded into an outer surface of one of the core visorbody half shells 24,26. These flanges may be arranged under theseinboard hooks and then the opposite end of the vanity frame 36 may besnapped or secured into place with a downward force, such that thelocking shoulders or locking surfaces of the vanity frame 36 mayinteract with the locking tabs, snaps or other locking surfaces moldedonto and into the visor half shell 24,26 thereof This may secure thevanity 28 into the visor body 22 with a snap in system that does notrequire fasteners, such as screws, to secure the vanity 28 to the visorbody 22. It should be noted that the vanity 28 of the present inventionmay include fasteners and screws to secure it to the visor body 22.

It should be noted that the visor half shell 24,26 that holds andsupports the vanity 28 also may include a circuit board pocket 64arranged on either one or both sides of the visor half shell near theorifice through which the vanity 28 is arranged. In one contemplatedembodiment shown in the figures, a rectangular shaped pocket 64 extendsa predetermined distance from an inside surface of one of the visor halfshells 24,26. In the embodiment shown, the circuit board pocket 64 isarranged on only one portion of the visor body half shell 24,26, howeverit should be noted that an identical circuit board pocket 64 may bearranged near an opposite end of the visor half shell in order to hold acircuit board 48 having an LED 46 thereon for an opposite side of themirror 42 arranged within the vanity 28. It should further be noted thatthe circuit board pocket 64 may have any known shape depending on theshape and size of the visor 20, such that the pocket 64 may have anyknown circular, square, rectangular, triangular, or any other known orunknown shape depending on the shape and size of the circuit board 48 tobe held and/or secured therein. It should be noted that the circuitboard 48 generally may be secured in the pocket 64 via a press fitconnection between the circuit board 48 and the inner surfaces of thecircuit board pocket 64. However, any other type of mechanical orchemical fastening technique or methodology may be used to secure thecircuit board 48 in a predetermined position with respect to the visorhalf shell 24,26 and in turn the visor mirror 42. It should further benoted that the use of other light bases, and components arranged on avisor half shell 24,26 may be used to hold the circuit board 48 for usein the present invention, such other options are disclosed inApplicant's prior filed U.S. application Ser. No. 14/996,530 filed onJan. 15, 2016, which Application is hereby incorporated by reference.The present invention may have the circuit board 48 secured and held ina predetermined position with respect to an end of the vanity mirror 42of the present invention. It is also contemplated that the circuit board48 may be secured or attached to the vanity frame 36. It is alsocontemplated that the LED 46 may be attached or secured directly to thevisor body 22, the vanity frame 36 or the mirror 42. A wire 40 may beconnected to the circuit board 48 on any side or end of the circuitboard 48. The top side or surface of the circuit board 48 may have a LED46 secured thereto and in electrical communication with the electronicsof the circuit board 48 and the electrical system of the vehicle. Themethodologies and manner of holding the circuit board 48 in apredetermined position with respect to the visor half shell 24,26 mayallow for the LED 46 to be held in place in the visor 20 in such aposition that it allows for light to be projected into an edge of themirror 42 at a predetermined position in conjunction with the vanity 28.The wires 40 connected to the circuit board 48 maybe fed and arrangedthrough any known wire channels or clips arranged on the visor halfshell 24,26, such that the wire 40 may have the ability to move freelywithin the sliding visor while being connected to the electrical systemof the vehicle.

Generally, in the prior art a lighted mirror consists of two lightbulbs, one on the left and one on the right side of the mirror such thata person's face is illuminated when they look into the vanity mirror 42.One embodiment of the present invention may use LED lights 46 on boththe left and right side of the vanity mirror 42, wherein the emittedlight may then travel all the way across the vanity mirror 42 and comeout the other side. The vanity mirror 42 of the present invention isdesigned such that total internal reflection occurs for light enteringone end of the vanity mirror 42 such that it may cross completely acrossthe vanity mirror 42 and come out the other side without any light beinglost in either the front or back surface of the vanity mirror 42. Thevanity mirror 42 may have a body with total internal reflection totransfer light from the LED 46 across the vanity mirror 42 and towardsthe face of the user. The present invention may eliminate the use oflight guides and only require either one, two or any other number ofLED's and a mirror 42 to be arranged and held within the vanity 28 of avisor 20 to allow for the mirror 42 to be a lighted vanity mirror 42that may have light emitted by a single LED 46 to illuminate the mirror42 and/or the person looking in the mirror in an aesthetically pleasingmanner.

The present invention is capable of using either one or two LED's 46,wherein one LED 46 may be arranged near only one end of the vanitymirror 42 while the two LED 46 system may have one LED 46 arranged atone end of the vanity mirror 42 and a second LED 46 arranged at thesecond end of the vanity mirror 42.

The vanity mirror 42 of the present invention generally may have arectangular or oval shape. However, it should be noted that any otherknown shape, such as square, round, triangular, or any other randomshape may be used for the mirror 42 depending on the requirements anddesign aspects of the vanity 28 for use in the visor 20 of the vehicle.The vanity mirror 42 may have any known length, width and thickness. Inone contemplated embodiment, the mirror 42 is approximately six and onehalf inches in length and two and one half inches in width andapproximately 0.2 inches or approximately five millimeters thick. Thebody of the vanity mirror 42 may have any other dimensions other thanthose described above from approximately one inch in length to many feetin length and from approximately one half inch in width up to many feetin width and from approximately two millimeters to many centimeters inthickness depending on the use for the mirror 42. It should be notedthat in one contemplated embodiment the mirror 42 is made of any knownacrylic or polycarbonate clear plastic. However, it should be noted thatany other known plastic, ceramic, composite, natural material or metal rgay be used to form the mirror body 42. The body of the vanity mirror 42may have an LED or other light source 46 arranged at an end of themirror 42 wherein the LED 46 emitted light may be totally internallyreflected across the entire length of the mirror 42 from one end to theopposite end, thus exiting at the opposite end of the vanity mirror 42.It should be noted that in one contemplated embodiment the vanity mirror42 maybe made of a generally clear material while the back side orsurface of the vanity mirror 42 may have a reflective material arrangedor placed thereon such as a reflective metal like aluminum or silver,etc. However, it should be noted that the body of the mirror 42 may alsohave the front surface mirrored with a reflective material instead ofthe back surface depending on the design requirements and the use of themirror 42. If the reflective material is on the front of the mirror 42,then it must not cover the light emitting areas 66. It should be notedthat generally arranged at or near each end of the vanity mirror 42 maybe a light emitting section or stripe 66. The light emitting portiongenerally maybe defined as a portion of the mirror 42 that does not havea reflective coating, tape or mirrored surface thereon. The lightemitting section 66 appears to be clear to the user of the mirror 42. Inone contemplated embodiment the light emitting portion 66 or stripe 66may be aligned vertically across the entire width of the mirror 42wherein this light emitting portion 66 may allow for light to beprojected from within the vanity mirror body towards the face of theuser of the vanity mirror 42. It is also contemplated that the lightemitting portion 66 may be arranged on the mirror 42 in any knownorientation or position not just vertically as shown. It should be notedthat these light emitting portions 66 may be arranged directly at eachend of the vanity mirror 42 or arranged a predetermined distance awayfrom each end of the vanity mirror 42 and it is also contemplated tohave only one light emitting portion 66 arranged at a predeterminedposition on the surface of the vanity mirror body. It should be notedthat in one contemplated embodiment the vanity mirror light emittingportions 66 generally have a rectangular shape, however any other knownshape, such as but not limited to oval, square, circular, triangular, orany other known or random shape may be used to define the light emittingportions or stripes 66 for the vanity mirror body of the presentinvention. The vanity mirror body of the present invention may have themirrored portion on either the back surface of the vanity mirror 42 orthe top surface of the vanity mirror 42 according to the presentinvention. It should further be noted that it is contemplated to paint,coat or apply a tape or other material to the back surface of the lightemitting portions 66 of the vanity mirror 42 a predetermined color toallow for an aesthetically pleasing look for the mirror 42 when used bythe vanity mirror user. It is contemplated that a white color or anyother neutral light color or a dark color may be used to coat the backsurface of the light emitting portion 66 of the vanity mirror 42.However, it is also contemplated that the color of the visor half shell24,26 may be predetermined to allow for an aesthetically pleasing lookto the user when the vanity mirror 42 is not illuminated. It is alsocontemplated that instead of using white some sort of reflective coatingmay also be placed on the back surface aligned with the light emittingportions 66 of the vanity mirror 42. The thickness of the vanity mirror42 may be determined upon the use of the vanity mirror 42 within thevisor 20. It should be rioted that generally the mirror 42 is planer andincludes one or more edges which are suitable for placement of a lightsource 46, preferably in the present invention an LED light source. Thismay allow the edge of the end of the vanity mirror 42 to facilitatelateral injection of light into the mirror body at approximately thesame plane as the mirror 42. In one contemplated embodiment, the lightinjection end may have an edge that is smooth and flat, however it isalso contemplated to include refracted optical features in order toinitiate wider light dispersion or narrower light dispersion, stillwithin the plane of the vanity mirror 42. It should further be notedthat in one contemplated embodiment the front surface of the mirror maybe completely smooth such that dirt and dust are easy to clean off anddoes not get caught on any rough surfaces. In one contemplatedembodiment, an LED or other light source 46 is placed at the lightinjection edge 68 located on at least one or maybe both ends of themirror 42, such that the light may enter the mirror 42 and traveldirectly across the mirror 42 via total internal reflection. The lightsource, such as an LED 46, in the mirror 42 may be placed within thevisor body 22 such that stray light from the LED 46 may not producedunwanted glare and such that the light source 46 stays in closeproximity to the light injection edge 68 of the visor vanity mirror 42.

The vanity mirror 42 of the present invention may also include one ormore ramps or channels 70 cut, molded, injection molded or machined intothe back surface of the vanity mirror 42. The ramps 70 may disrupt thetotal internal reflection of the mirror 42 in the vicinity of the ramp70 thus allowing for light to be distributed out the front of the mirror42 at this location to illuminate the vanity mirror 42 and the user'sface. It should be noted that other optical features capable ofdisrupting the total internal reflection of the mirror 42 may also beused such as but not limited to bonding a light guide film on the lightemitting area 66, etc. In one contemplated embodiment, a first ramp 70is located at or near a first end of the vanity mirror 42 and a secondramp 70 is located at or near a second end of the vanity mirror 42. Itshould be noted that the ramps 70 generally align with and define thelight emitting portions 66 arranged on the vanity mirror 42. The ramps70 create a disruption in the total internal reflection of the vanitymirror body and thus evenly illuminate the user of the vanity mirror 42.The ramps 70 of the present invention generally are large and extend apredetermined distance into the back surface of the mirror 42 so as tocapture a high percentage of the light emitted from the light emittingdiode 96 such that not much light may be wasted by traveling all the wayacross the mirror 42 and out the edges of the vanity mirror 42. Anylight that is lost out of the edges of the vanity mirror 42 is wastedlight in the application of an illuminated vanity mirror 42. In oneembodiment contemplated a LED 46 is arranged on each end and at eachedge of the vanity mirror 42 and a first and second ramp 70 may bearranged near each end of the vanity mirror 42 into a back surfacethereof It should be noted that the first and second ramp 70 may eachinclude a first inward extending surface extending at a predeterminedangle from the back surface of the mirror 42. Each ramp 70 may alsoinclude a second inward extending surface extending at a predeterminedangle from the back surface of the mirror 42. It should be noted thatthe two surfaces may meet at a predetermined depth within the thicknessof the vanity mirror 42. In the embodiment shown the mirror thickness isapproximately 0.118 inches and the ramp 70 extends into the back surfaceof the mirror 42 0.78 inches thus it extends deeply into the mirror 42to allow for almost complete redirection of the light being emitted fromthe LED 46 towards the face of the user of the vanity mirror 42. In thiscase, the first or longer surface of the ramp 70 may be arranged closestto the end of the vanity mirror 42 with a LED 46 thereby thus allowingfor near complete redirection of the total internal reflection (TIR)light towards the user of the vanity mirror 42. Any light that escapesbeyond the ramp 70 would directly travel across the vanity mirror 42 tothe other ramp 70. It should be noted that as described above, the backsurface of the mirror 42 has the ramps 70 arranged directly adjacent toand aligned with the light emitting portions 66. As noted above, theramp 70 may be painted white or any other desired color to improve theaesthetics of the mirror 42 when the LED's are turned off. It shouldfurther be noted that ripples, ridges or any other features may bearranged, machined and/or molded directly onto the surface of the ramps70. These surfaces, ripples or ridges may be well defined and mayimprove the aesthetics as well as make the light output somewhat lesssensitive to changes in the surface roughness of the ramps 70 arrangedwithin the back surface of the vanity mirror 42. It should be noted thatthe angle at which the first and second inward extending surfaces enterthe back surface of the mirror 42 may be in the approximate range ofzero to ninety degrees with relation to the back surface of the mirror42. It should be noted that the angle may be determined based on thedesign and the amount of light to be redirected towards the user of thevanity mirror 42.

In an embodiment, it is contemplated to use one LED 46 instead of two toprovide light from a first and second light emitting portion 66 as shownin the figures of the present invention. It should be noted that for thedual LED embodiment each side had ramps 70 that were made with the longgentle side of the ramp 70 facing the LED 46. These ramps 70 were cutdeeply into the mirror body 42 so that a minimum amount of light wouldtransit over the top of the ramp 70 and travel to the ramp 70 on theopposite side of the vanity mirror 42. In the embodiment that uses onlyone LED 46 to provide light to both sides of the vanity mirror 42, theramp 70 on the side that includes the LED 46 arranged at the end thereofwould be cut much less deeply into the vanity mirror back surface. Inone contemplated embodiment, if a mirror thickness is approximately 4.5millimeters the first ramp 70 would be arranged at a depth ofapproximately two millimeters into the back surface of the vanity mirror42 while approximately 2.5 millimeters of the mirror body material wouldstill be intact above the top of the first ramp 70. In this case,approximately one half of the light from the LED 46 may transit past thefirst ramp 70, thus traveling by TIR all the way across the mirror 42 tothe opposite side of the mirror 42 and the second ramp 70 arranged onthe opposite end of the mirror 42 which may be cut in the same oropposite direction as the first ramp 70 on the first end of the mirror42. The second ramp 70 maybe arranged almost or all of the way throughor into the thickness of the mirror's back surface in order to maximizethe amount of light which is redirected from the second ramp 70 throughthe back clear portion 66 towards the user of the vanity mirror.Furthermore, this would only allow all percentage of light to be wastedas it traverses past the second ramp 70. In this embodiment, the usermay perceive equal illumination from both sides while only using one LED46. Therefore, the ramps 70 may or may not face and be aligned in thesame direction when one LED 46 is used to illuminate both sides of avanity mirror 42. The LED 46 may have the same configuration as thosedescribed above for the two LED embodiments. Therefore, in the singleLED 46 embodiment approximately half of the light may be directed fromeach end or side of the mirror 42 towards the face of the user of thevanity mirror 42. It should be noted that the dimensions given are justone contemplated embodiment and that any other dimensions and depth ofeither the first or second ramp may be used. Generally, the second ramp70 may extend more deeply into the back surface of the vanity mirror 42than the first ramp 70 in order to allow for the light to be redirectedthrough both ends of the vanity mirror light emitting portions 66arranged on each end of the vanity mirror 42. It should be noted that asplit of the light other than 50/50 on each side or end of the mirrormay also be used and may easily be altered by varying the depth of thefirst ramp 70. The use of a single LED 46 may allow for the entirevanity mirror 42 length to be shortened which may reduce the cost of thevanity mirror 42. It is also contemplated that by increasing the angleof the transition area on the end of the vanity mirror 42 that has theLED 46 arranged thereby from an included angle of approximately fortyeight degrees to an included angle of approximately one hundred twentydegrees may have little or no loss of performance since the LED 46generally has a beam spread angle of approximately one hundred twentydegrees. It should be noted that in the one LED embodiment the end ofthe mirror 42 that may have the light emitted diode 46 arranged therebymay have a generally a triangular shape when viewed from a back of themirror 42. The light entry point 68 may have a flat smooth surfacehowever any other concave surface may be used depending on the LED 46.It should be noted that one end of the generally triangular shape andmay start at an edge of a ramp 70. It should further be noted that anyother shape may be used for the end of the mirror 42 that may receivethe light therein and that any known included angle from approximatelytwenty to one hundred ninety degrees may be used depending on the LED 46used in conjunction therewith. It should further be noted that thevanity mirror 42 may also include a first and second notch 72 arrangedgenerally near or at a first and second end on an edge thereof. Thenotches 72 may be used to help secure the vanity mirror 42 within thevanity frame 36 near the first and second locking shoulders 56 of thevanity frame 36. It should be noted that generally the notches 72 have asemi-circular shape but the shape may be any shape that corresponds tothe locking surfaces arranged from the vanity frame 36. The use of thesenotches 72 may help to secure the vanity mirror 42 in a predeterminedposition with relation to the vanity frame 36 and hence, the visor body22. Generally, the ramps 70 when viewed from a side form a wedge likeshape into the back surface of the vanity mirror 42 unless the ramp 70is arranged directly at the end of the mirror 42 then the ramp 70 mayform a generally angled end in the back surface of the vanity mirror 42.The mirror 42 may have a coating or film on the outer visible surfacethereof to reduce or eliminate scratching of the outer visible surfaceof the mirror 42. This scratch mitigating feature may or may not be usedon the mirror 42.

It should be noted that the light emitting diode 46 arranged on thecircuit board 48 of the present invention may emit light directly intoeither one or two of the mirror body edges and have that light travelacross the plane of the mirror 42 via total internal reflection. Thedesign may allow for the emitted light to be redirected via ramps 70arranged in predetermined positions in the back surface of the vanitymirror 42 which may disrupt the total internal reflection and allow forthe light to be scattered and emitted through the light emittingportions 66 of the vanity mirror 42 toward the user of the vanity mirror42. The ramps 70 arranged within the visor vanity mirror body may allowfor the total internal reflection of the mirror body to be disrupted andallow for a high percentage of the light to be captured and redirectedif a two LED system is used or for almost all of the light to becaptured and evenly divided between the left and right side of a vanitymirror 42 if a one LED 46 system is used thus providing for anaesthetically pleasing and consistent illumination of the user's face.Therefore, the vanity mirror 42 of the present invention may use eitherone or two LED 46 and with the LED being very small and inexpensive tomanufacture less wiring may be required. The use of the ramps 70arranged directly in the vanity mirror body may cause a high percentageof the light to be redirected in the direction of the target, such thatnot much light from the LED's may be wasted as stray light within thevisor body 22. The use of one or two individual LED's 46 may besufficient to illuminate the user of the vanity at the customer'sspecified light levels of approximately sixteen lux. The use of theramps 70 as a TIR disruption feature may be inexpensive to produce sincethey can be molded, cut or machined directly into the back surface ofthe mirrors 42. Furthermore, the mirroring and illumination of themirror 42 may be done in large sheets for easier manufacturing of thevanity mirror 42 for the manufacturer. It should further be noted thatwith the present invention the light directed toward the user's face maybe diffuse and pleasing with a minimum amount of glare such that nointense bright spots may be evident in the case of looking right at theLED 46 which may he too blinding to be practical in an illuminated visormirror. With the mirror 42 being smooth on the front side including theareas where the light is released from may allow for illumination of themirror and the user's face while looking at the mirror 42. The use ofthe vanity mirror 42 as described herein may reduce the number of partsneeded to create the illuminated sliding visor according to the presentinvention. A single mirror 42 and as little as one LED light source 46may be used to illuminate a mirror 42 instead of some prior art visorsthat use two light bulbs, two light bulb sockets, the associated wiring,the associated lens covers, along with associated light guides for eachend thereof. It should further be noted that the ramps 70 of the presentinvention generally extend across the entire width of the backside ofthe vanity mirror 42. However, it should be noted that it is alsocontemplated that only a predetermined portion of the width of thevanity mirror 42 may have the ramp 70 arranged thereon depending on howthe light is to be projected towards the user's face of the vanitymirror 42. It should further be noted that more than two ramps 70 may beused in the contemplated embodiment of the vanity mirror 42 and aslittle as one ramp 70 may also be used in another contemplatedembodiment of the vanity mirror 42 according to the present invention.Furthermore, the depth at which the ramps 70 extend into the backsurface of the mirror 42 may be any known depth depending on the amountof light needed to be redirected towards the user of the interface atany number of predetermined light emitting portions 66 arranged in thesurface of the mirror body.

Therefore, in operation, the embodiments of the visor 20 describedherein may be easier to manufacture and easier to have the vanitiesinstalled therein, via a snap in locking system deployed in both theframeless vanity and the locking vanity frame embodiments disclosed.Such easy installation of the vanities and easy use of the LED 46 toilluminate such vanities within the visor bodies may reducemanufacturing time and reduce the overall costs and number of parts forthe manufacturer while also allowing the reduction in costs andmaterials as the clear ends 66 of the mirror 42 allow for a removal ofany lenses and associated hardware connected to the lenses and/or lightguides that may be used in conjunction with a LED 46 in the prior art.

The present invention has been described in an illustrative manner. Itis to be understood that the terminology which has been used is intendedto be in the nature of words of description rather than that oflimitation.

Many modifications and variations of the present invention are possiblein light of the above teachings. Therefore, within the scope of theappended claims, the present invention may be practiced otherwise thanas specifically described.

What is claimed is:
 1. A mirror, said mirror comprising: a predeterminedshape body having a first end and a second end, said body having totalinternal reflection; a light emitting portion arranged at or near saidfirst end of said body; and a ramp arranged in a back surface of saidbody, said ramp aligned with said light emitting portion.
 2. The mirrorof claim 1 wherein said body having a second ramp arranged in said backsurface at or near said second end.
 3. The mirror of claim 1 whereinsaid body having a generally triangular shape at said end, said endhaving a predetermined included angle.
 4. The mirror of claim 1 whereinsaid ramp having a first inward extending surface with a predeterminedangle from said back surface.
 5. The mirror of claim 4 wherein saidfirst inward extending surface extends a first distance into said backsurface of said mirror.
 6. The mirror of claim 5 wherein said ramphaving a second inward extending surface with a predetermined angle fromsaid back surface, said second inward extending surface and said firstinward extending surface meet at said first distance of said backsurface of said mirror.
 7. The mirror of claim 1 wherein said ramphaving a smooth, rippled or ridged surface.
 8. The mirror of claim 1wherein said ramp having a predetermined color.
 9. The mirror of claim 2wherein said second ramp having a first inward extending surface with apredetermined angle from said back surface, said first inward extendingsurface extends a second distance into said back surface of said mirror.10. The mirror of claim 9 wherein said second ramp having a secondinward extending surface with a predetermined angle from said backsurface, said first inward extending surface and said second inwardextending surface meet at said second distance.
 11. The mirror of claim1 wherein said ramp extends between a generally top and bottom edge ofsaid mirror.
 12. The mirror of claim 1 wherein said ramp redirects apredetermined amount of light entering through said first end of saidbody through a front surface of said mirror at said light emittingportion thereof.
 13. The mirror of claim 12 wherein a second rampredirects a predetermined amount of light entering through said secondend of said body through said front surface of said mirror at a secondlight emitting portion thereof.
 14. The mirror of claim 12 whereinapproximately one half of said predetermined amount of light isredirected by said ramp.
 15. The mirror of claim 14 comprising a secondramp arranged in said back surface of said body, said second rampredirects other approximately one half of said predetermined amount oflight through said front surface of said mirror at a second lightemitting portion thereof.
 16. The mirror of claim 1 wherein said firstend having a transition area with a light entry point at an end thereof.17. The mirror of claim 16 wherein said transition area having anincluded angle between approximately forty eight degrees andapproximately one hundred twenty degrees.
 18. The mirror of claim 1further comprising at least one notch arranged on an edge of said body.19. The mirror of claim 16 further comprising a second transition areaarranged on said second end of said body, said second transition areahaving a second light entry point.
 20. A method of illuminating amirror, said method comprising the steps of: cutting or molding opticalfeatures into a back surface of the mirror, the mirror having totalinternal reflection, said optical features define light emitting areasof the mirror; and using light from a single light source for emissionthrough said light emitting areas of the mirror toward a user of themirror.